Composite Part Forming System

ABSTRACT

A system and method for forming a composite part. The method comprises positioning a prepreg material relative to a composite forming tool. The composite forming tool comprises a frame associated with a shaping system, a base comprising at least one mold, and the shaping system associated with the frame and configured to move relative to the frame, the base, and the prepreg material. The method also lowers the shaping system of the composite forming tool towards the prepreg material. The method applies pressure to the prepreg material with a centerline presser of the shaping system. The method also applies a force to the prepreg material using a number of compliant elongate members of the shaping system to uniformly apply the prepreg material to the at least one mold of the base of the composite forming tool.

BACKGROUND INFORMATION

1. Field

The present disclosure relates generally to manufacturing compositestructures. More particularly, the present disclosure relates to amethod and apparatus for laying up a number of plies of compositematerial on a number of molds.

2. Background

Aircraft are being designed and manufactured with greater and greaterpercentages of composite materials. Composite materials are used inaircraft to decrease the weight of the aircraft. This decreased weightimproves performance features such as payload capacities and fuelefficiencies. Further, composite materials provide longer service lifefor various components in an aircraft.

Composite materials are tough, lightweight materials created bycombining two or more functional components. For example, a compositematerial may include reinforcing fibers bound in polymer resin matrix.The fibers may be unidirectional or may take the form of a woven clothor fabric.

In manufacturing composite parts, layers of composite material aretypically laid up on a tool. The layers may be comprised of fibers insheets. These sheets may take the form of fabrics, tape, tows, or othersuitable forms. In some cases, resin may be infused or preimpregnatedinto the sheets. These types of sheets are commonly referred to asprepreg.

There are currently several techniques for laying up and compactingcomposite prepreg plies on a tool. Composite plies may be laid up usingautomated fiber placement machines or tape laminating machines, butthese machines are large, expensive and require intricate programmingand significant validation. Further, these machines progressively lay-upplies using tape or fiber with a smaller width than the completed ply.In other words, automated fiber placement machines or tape laminatingmachines lay up individual tape or fiber portions to form a ply.Currently, laying up whole prepreg sheets or plies is accomplished byhand layup. Hand layup of plies is possible, but time-consuming, laborintensive, and may be inaccurate and/or inconsistent.

Accordingly, there is a need for a method and apparatus that automatesthe process of laying up composite plies. There is also a need for amethod and apparatus of the type mentioned above that minimizes oreliminates the need for human intervention and supervision, whileproviding consistent and accurate ply placement.

Therefore, it would be desirable to have a method and apparatus thattake into account at least some of the issues discussed above, as wellas other possible issues. For example, it would be desirable to have amethod and apparatus that take into account technical problems thatoccur with at least one of the manual layup of composite parts orcurrently used composite part layup systems.

SUMMARY

An illustrative embodiment of the present disclosure provides a methodfor forming a composite part. The method comprises positioning a prepregmaterial relative to a composite forming tool. The composite formingtool comprises a frame associated with a shaping system, a basecomprising at least one mold, and the shaping system associated with theframe and configured to move relative to the frame, the base, and theprepreg material. The method also lowers the shaping system of thecomposite forming tool towards the prepreg material. The method appliespressure to the prepreg material with a centerline presser of theshaping system. The method also applies a force to the prepreg materialusing a number of compliant elongate members of the shaping system touniformly apply the prepreg material to the at least one mold of thebase of the composite forming tool.

A further illustrative embodiment of the present disclosure provides anapparatus. The apparatus comprises a base, a frame, and a shapingsystem. The base comprises at least one mold. The frame positions theshaping system relative to the base. The shaping system is associatedwith the frame. The shaping system moves relative to the frame, thebase, and a prepreg material positioned relative to the base. Theshaping system comprises a centerline presser and a number of compliantelongate members. The centerline presser moves relative to the prepregmaterial along a vertical axis to apply pressure to the prepregmaterial. The number of compliant elongate members moves relative to thecenterline presser and the prepreg material and applies controlled forceto the prepreg material to uniformly apply the prepreg material to theat least one mold.

Another illustrative embodiment of the present disclosure providesanother method for forming a composite part. The method comprisespositioning a prepreg material on a carrier relative to a compositeforming tool. The composite forming tool comprises a frame associatedwith a shaping system, a base comprising at least one mold, and theshaping system associated with the frame and configured to move relativeto the frame, the base, and the carrier. The method also lowers theshaping system of the composite forming tool towards the prepregmaterial. The method contacts the carrier with a centerline presser ofthe shaping system. The method also uniformly applies the prepregmaterial to the at least one mold of the base of the composite formingtool using a number of compliant elongate members of the shaping system.Uniformly applying the prepreg material comprises moving the number ofcompliant elongate members of the shaping system relative to the prepregmaterial along a horizontal axis using a number of actuators connectedto the centerline presser, and applying a force to the prepreg materialusing the number of compliant elongate members of the shaping system,wherein the force is approximately normal to a surface of the at leastone mold of the base.

The features and functions can be achieved independently in variousembodiments of the present disclosure or may be combined in yet otherembodiments in which further details can be seen with reference to thefollowing description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the illustrativeembodiments are set forth in the appended claims. The illustrativeembodiments, however, as well as a preferred mode of use, furtherobjectives and features thereof, will best be understood by reference tothe following detailed description of an illustrative embodiment of thepresent disclosure when read in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is an illustration of an aircraft in accordance with anillustrative embodiment;

FIG. 2 is an illustration of a block diagram of a manufacturingenvironment in accordance with an illustrative embodiment;

FIG. 3 is an illustration of a physical implementation of amanufacturing environment in accordance with an illustrative embodiment;

FIG. 4 is an illustration of a cross-sectional isometric view of acomposite forming tool in accordance with an illustrative embodiment;

FIG. 5 is an illustration of a cross-sectional front view of a compositeforming tool in accordance with an illustrative embodiment;

FIG. 6 is an illustration of a cross-sectional front view of a compositeforming tool in accordance with an illustrative embodiment;

FIG. 7 is an illustration of a cross-sectional front view of a compositeforming tool in accordance with an illustrative embodiment;

FIG. 8 is an illustration of a cross-sectional front view of a compositeforming tool in accordance with an illustrative embodiment;

FIG. 9 is an illustration of a cross-sectional front view of a compositeforming tool in accordance with an illustrative embodiment;

FIG. 10 is an illustration of a cross-sectional front view of acomposite forming tool in accordance with an illustrative embodiment;

FIG. 11 is an illustration of a cross-sectional front view of acomposite forming tool in accordance with an illustrative embodiment;

FIG. 12 is an illustration of a cross-sectional front view of acomposite forming tool in accordance with an illustrative embodiment;

FIG. 13 is an illustration of a cross-sectional front view of acomposite forming tool in accordance with an illustrative embodiment;

FIG. 14 is an illustration of a carrier and a composite forming tool ina manufacturing environment in accordance with an illustrativeembodiment;

FIG. 15 is an illustration of a carrier and a composite forming tool ina manufacturing environment in accordance with an illustrativeembodiment;

FIG. 16 is an illustration of a carrier and a composite forming tool ina manufacturing environment in accordance with an illustrativeembodiment;

FIG. 17 is an illustration of a carrier and a composite forming tool ina manufacturing environment in accordance with an illustrativeembodiment;

FIG. 18 is an illustration of a carrier and a composite forming tool ina manufacturing environment in accordance with an illustrativeembodiment;

FIG. 19 is an illustration of a vent stringer formed on a compositeforming tool in accordance with an illustrative embodiment;

FIG. 20 is an illustration of a blade stringer formed on a compositeforming tool in accordance with an illustrative embodiment;

FIG. 21 is an illustration of a blade stringer formed on a compositeforming tool in accordance with an illustrative embodiment;

FIG. 22 is an illustration of a flowchart of a process for forming acomposite part in accordance with an illustrative embodiment;

FIG. 23 is an illustration of a flowchart of a process for forming acomposite part in accordance with an illustrative embodiment;

FIG. 24 is an illustration of a block diagram of an aircraftmanufacturing and service method in accordance with an illustrativeembodiment; and

FIG. 25 is an illustration of a block diagram of an aircraft in which anillustrative embodiment may be implemented.

DETAILED DESCRIPTION

The illustrative embodiments recognize and take into account one or moredifferent considerations. The illustrative embodiments recognize andtake into account that laying up composite parts by hand is at least oneof undesirably slow, undesirably expensive, prone to inconsistencies, orinaccurate.

The illustrative embodiments also recognize and take into account thatmanufacturing space has a cost. The illustrative embodiments furtherrecognize and take into account that undesirably large machinery maytake up a large amount of valuable and expensive manufacturing space.Accordingly, the illustrative embodiments recognize and take intoaccount that minimizing the size of composite manufacturing equipmentmay be desirable.

Further, the illustrative embodiments recognize and take into accountthat female composite parts laid up on a male tool may require an extrahandling step to remove the female composite part before the femalecomposite part can be cured. This extra handling step may increase atleast one of manufacturing time, manufacturing cost, or inconsistenciesin the resulting female composite part. Yet further, the illustrativeembodiments recognize and take into account that forming a femalecomposite part on a male tool uses the inner mold line to be thedefining characteristic. As a result, forming a female composite part ona male tool may result in undesirable quality on the exterior of thefemale part. Thus, the illustrative embodiments recognize and take intoaccount that forming a female composite part on a female mold isdesirable.

The illustrative embodiments recognize and take into account thatconventional composite manufacturing equipment cannot produce femalecomposite parts having desirable quality using female molds.Conventional composite manufacturing equipment forming female compositeparts on female molds results in composite parts with wrinkles, voids,tears, undesirable shapes, or other inconsistencies.

The illustrative embodiments further take into account that a finishedlayup may have an expected “bulk factor.” A “bulk factor” is thedifference in volume between the part as it has been laid up and atheoretical part formed from the composite material. If this “bulkfactor” varies undesirably across the uncured or unconsolidated part, itmay cause inconsistencies. For example, undesirable variation in the“bulk factor” may distort the final cured part.

Inconsistencies such as an inconsistent bulk factor, wrinkles, voids,tears, undesirable shapes, or other inconsistencies may increasemanufacturing cost by increasing discarded parts or by increasing thenumber of reworks. Inconsistencies such as an inconsistent bulk factor,wrinkles, voids, tears, undesirable shapes, or other inconsistencies mayincrease manufacturing time as a result of reworking or creating newparts after discarding parts of undesirable quality.

Yet further, the illustrative embodiments recognize and take intoaccount that composite forming equipment which forms composite partshaving a variety of shapes may be desirable. Additionally, theillustrative embodiments recognize and take into account that compositeforming equipment which forms composite parts of different shapes mayreduce manufacturing costs.

With reference now to the figures, and in particular, with reference toFIG. 1, an illustration of an aircraft is depicted in accordance with anillustrative embodiment. In this illustrative example, aircraft 100 haswing 102 and wing 104 attached to body 106. Aircraft 100 includes engine108 attached to wing 102 and engine 110 attached to wing 104.

Body 106 has tail section 112. Horizontal stabilizer 114, horizontalstabilizer 116, and vertical stabilizer 118 are attached to tail section112 of body 106.

Aircraft 100 is an example of an aircraft in which a composite part maybe implemented in accordance with an illustrative embodiment. Forexample, the composite part may take the form of stiffeners 120associated with composite skin 122 of aircraft 100. FIG. 1 depicts anexposed view of stiffeners 120. Although not depicted, in someillustrative examples, stiffeners 120 may also be associated with one ofwing 102, wing 104, horizontal stabilizer 114, horizontal stabilizer116, or vertical stabilizer 118.

The illustration of aircraft 100 is provided for purposes ofillustrating one environment in which the different illustrativeembodiments may be implemented. The illustration of aircraft 100 in FIG.1 is not meant to imply physical or architectural limitations to themanner in which different illustrative embodiments may be implemented.For example, aircraft 100 is shown as a commercial passenger aircraft.The different illustrative embodiments may be applied to other types ofaircraft, such as private passenger aircraft, a rotorcraft, and othersuitable types of aircraft.

Turning now to FIG. 2, an illustration of a block diagram of amanufacturing environment is depicted in accordance with an illustrativeembodiment. Composite parts such as stiffeners 120 of FIG. 1 may bemanufactured in manufacturing environment 200. Manufacturing environment200 may be used to form a variety of composite parts.

Manufacturing environment 200 has composite forming tool 202. Compositeforming tool 202 may form composite part 203. Composite part 203 maytake the form of stringer 204. Composite forming tool 202 formscomposite part 203, such as stringer 204, from composite material 206.Carrier 208 carrying ply 210 of composite material 206 may be placedinto composite forming tool 202 by carrier placement system 212. Carrierplacement system 212 may move carrier 208 so that it is positionedbetween frame 214 and base 216 of composite forming tool 202.

Composite forming tool 202 includes frame 214, base 216, and axialmovement system 218. Axial movement system 218 moves one of frame 214and base 216 relative to the other along longitudinal axis 220 ofcomposite forming tool 202. Axial movement system 218 may include motor222 to facilitate movement of one of frame 214 and base 216 relative tothe other. Axial movement system 218 may include at least one of numberof wheels 224 and number of rails 226.

As used herein, the phrase “at least one of,” when used with a list ofitems, means different combinations of one or more of the listed itemsmay be used and only one of each item in the list may be needed. Forexample, “at least one of item A, item B, or item C” may include,without limitation, item A, item A and item B, or item B. This examplealso may include item A, item B, and item C or item B and item C. Ofcourse, any combinations of these items may be present. In otherexamples, “at least one of” may be, for example, without limitation, twoof item A; one of item B; and ten of item C; four of item B and seven ofitem C; or other suitable combinations. The item may be a particularobject, thing, or a category. In other words, at least one of means anycombination of items and number of items may be used from the list butnot all of the items in the list are required.

In some examples, number of wheels 224 may be associated with frame 214.In these examples, frame 214 may roll along longitudinal axis 220relative to base 216. Frame 214 may move relative to base 216 to placecomposite material 206 on another section of base 216. Specifically,length 228 of frame 214 may be less than length 230 of base 216. Thus,to apply composite material 206 along length 230 of base 216, frame 214must apply composite material 206 incrementally along length 230.Accordingly, frame 214 translates along longitudinal axis 220 to applycomposite material 206 along length 230 of base 216.

In some examples, number of rails 226 may be associated with at leastone of frame 214 or base 216. In these examples, one of frame 214 orbase 216 moves along longitudinal axis 220 relative to the other alongnumber of rails 226. One of frame 214 or base 216 may move relative tothe other along longitudinal axis 220 on number of rails 226 to applycomposite material 206 along length 230 of base 216.

Frame 214 is associated with shaping system 232 and movement system 233.Frame 214 positions shaping system 232 relative to base 216.Specifically, positioning frame 214 relative to base 216 alonglongitudinal axis 220 may also position shaping system 232 relative tobase 216. Movement system 233 moves shaping system 232 along verticalaxis 234 relative to base 216. Movement system 233 may move shapingsystem 232 along vertical axis 234 such that shaping system 232 may actupon composite material 206. In some illustrative examples, movementsystem 233 may include an actuator. In these illustrative examples,movement system 233 may control the force applied by shaping system 232using the actuator.

Shaping system 232 applies a force to composite material 206 touniformly apply composite material 206 to base 216. A material isuniformly applied when substantially all of a surface of the materialcontacts the surface of base 216. Further, a material is “uniformlyapplied” when the material is subjected to a known and repeatable force,over the entirety of the area of the material. The applied force wouldbe desirably applied such that inconsistencies are minimized incomposite material 206. Examples of inconsistencies may include at leastone of generating wrinkles, tears, over-compacted areas, under-compactedareas, bubbles, fiber distortions, or other undesirable features.

Uniform application may be force, time, and heat dependent. Shapingsystem 232 includes first force application assembly 235, second forceapplication assembly 236, and centerline presser 238. Centerline presser238 is associated with movement system 240. Movement system 240 may movecenterline presser 238 along vertical axis 234 relative to first forceapplication assembly 235 and second force application assembly 236.Further, movement system 240 may move centerline presser 238 alongvertical axis 234 relative to frame 214 and base 216. Centerline presser238 may apply pressure to at least one of composite material 206 orcarrier 208 prior to uniformly applying composite material 206 to base216.

First force application assembly 235 has first number of compliantelongate members 242 and first movement system 243. First number ofcompliant elongate members 242 may be one or more compliant elongatemembers. In illustrative examples in which first number of compliantelongate members 242 is more than one compliant elongate member, each ofthe compliant elongate members is connected together to form a singleforming surface. First number of compliant elongate members 242 hasforming surface 244 which impacts at least one of composite material 206or carrier 208. First movement system 243 may move first number ofcompliant elongate members 242 relative to frame 214, base 216, andcenterline presser 238 to uniformly apply composite material 206 to base216. Specifically, first movement system 243 may move first number ofcompliant elongate members 242 along horizontal axis 246 relative tobase 216. First number of compliant elongate members 242 contactscenterline presser 238 in a resting position. First movement system 243may move first number of compliant elongate members 242 in a sweepingmotion away from centerline presser 238 along horizontal axis 246. Firstmovement system 243 may also adjust an angle of first number ofcompliant elongate members 242 relative to base 216. First movementsystem 243 may control a position and an angle of first number ofcompliant elongate members 242. Movement system 233 may control theforce applied by a compliant elongate member in first number ofcompliant elongate members 242 using an actuator.

First movement system 243 includes first number of arms 248, firstnumber of actuators 250, second number of arms 252, and second number ofactuators 254. First number of actuators 250 may be attached at the endof first number of arms 248. First number of arms 248 may be directlyconnected to centerline presser 238 such that centerline presser 238acts as a strongback. A strongback acts as a support structure. In thisexample, centerline presser 238 acts as a support structure, or spine,being used for its rigidity. Forces imparted to first number ofcompliant elongate members 242 may be reacted through centerline presser238. These forces may be reacted through centerline presser 238 due tothe rigidity of centerline presser 238. Further, these forces may bereacted through centerline presser 238 due to the connection of firstnumber of arms 248 to centerline presser 238. First number of actuators250 may extend through centerline presser 238. First number of actuators250 may be directly connected to first number of compliant elongatemembers 242. First number of actuators 250 may move a compliant elongatemember of first number of compliant elongate members 242 relative tocenterline presser 238.

Second number of actuators 254 may be attached at the end of secondnumber of arms 252. Second number of arms 252 may be directly connectedto centerline presser 238 such that centerline presser 238 acts as astrongback. The forces imparted to first number of compliant elongatemembers 242 may be reacted through centerline presser 238 due to therigidity of centerline presser 238. These forces may be reacted throughcenterline presser 238 due to the connection of second number of arms252 to centerline presser 238. Second number of actuators 254 may extendthrough centerline presser 238. Second number of actuators 254 may bedirectly connected to first number of compliant elongate members 242.First movement system 243 may control a position and an angle of firstnumber of compliant elongate members 242 using at least one of firstnumber of actuators 250 and second number of actuators 254. In someillustrative examples, a number of first number of actuators 250 maymove a first compliant elongate member of first number of compliantelongate members 242 relative to centerline presser 238.

Second force application assembly 236 has second number of compliantelongate members 256 and second movement system 258. Second number ofcompliant elongate members 256 may be one or more compliant elongatemembers. In illustrative examples in which second number of compliantelongate members 256 is more than one compliant elongate member, each ofthe compliant elongate members is connected together to form a singleforming surface. Second number of compliant elongate members 256 hasforming surface 260 which impacts at least one of composite material 206or carrier 208. Second movement system 258 may move second number ofcompliant elongate members 256 relative to frame 214, base 216, andcenterline presser 238 to apply composite material 206 to base 216.Specifically, second movement system 258 may move second number ofcompliant elongate members 256 along horizontal axis 246 relative tobase 216. Second number of compliant elongate members 256 contactscenterline presser 238 in a resting position. Second movement system 258may move second number of compliant elongate members 256 in a sweepingmotion away from centerline presser 238 along horizontal axis 246.Second movement system 258 may also adjust an angle of second number ofcompliant elongate members 256 relative to base 216. Second movementsystem 258 may control a position and an angle of second number ofcompliant elongate members 256. Movement system 233 may control theforce applied by a compliant elongate member in second number ofcompliant elongate members 256 using an actuator.

Second movement system 258 includes third number of arms 262, thirdnumber of actuators 264, fourth number of arms 266, and fourth number ofactuators 268. Third number of actuators 264 may be attached at the endof third number of arms 262. Third number of arms 262 may be directlyconnected to centerline presser 238 such that centerline presser 238acts as a strongback. Forces imparted to second number of compliantelongate members 256 may be reacted through centerline presser 238.These forces may be reacted through centerline presser 238 due to therigidity of centerline presser 238. Further, these forces may be reactedthrough centerline presser 238 due to the connection of third number ofarms 262 to centerline presser 238. Third number of actuators 264 mayextend through centerline presser 238. Third number of actuators 264 maybe directly connected to second number of compliant elongate members256.

Fourth number of actuators 268 may be attached at the end of fourthnumber of arms 266. Fourth number of arms 266 may be directly connectedto centerline presser 238 such that centerline presser 238 acts as astrongback. The forces imparted to second number of compliant elongatemembers 256 may be reacted through centerline presser 238 due to therigidity of centerline presser 238. These forces may be reacted throughcenterline presser 238 due to the connection of fourth number of arms266 to centerline presser 238. Fourth number of actuators 268 may extendthrough centerline presser 238. Fourth number of actuators 268 may bedirectly connected to second number of compliant elongate members 256.Second movement system 258 may control a position and an angle of secondnumber of compliant elongate members 256 using at least one of thirdnumber of actuators 264 and fourth number of actuators 268.

Number of vertical arms 270 is associated with first force applicationassembly 235 and second force application assembly 236. For example,number of vertical arms 270 may be connected to first force applicationassembly 235 and second force application assembly 236 through a plate.Number of vertical arms 270 may move first number of compliant elongatemembers 242 and second number of compliant elongate members 256 alongvertical axis 234. Number of vertical arms 270 may facilitate firstnumber of compliant elongate members 242 and second number of compliantelongate members 256 applying force to composite material 206.

Number of vertical arms 270 and first movement system 243 may directfirst number of compliant elongate members 242 such that forming surface244 follows the surface of base 216 to uniformly apply compositematerial 206 to base 216. Number of vertical arms 270 and secondmovement system 258 may direct second number of compliant elongatemembers 256 such that forming surface 260 follows the surface of base216 to uniformly apply composite material 206 to base 216. Theinteraction of number of vertical arms 270, first movement system 243,and second movement system 258 move forming surface 244 and formingsurface 260 to apply a desired amount of force to composite material206.

Number of vertical arms 270, first movement system 243, and secondmovement system 258 may direct first number of compliant elongatemembers 242 and second number of compliant elongate members 256 suchthat forming surface 244 and forming surface 260, respectively, move ina sweeping motion away from centerline presser 238. The connectionsbetween first movement system 243 and second movement system 258 mayfacilitate application of a desired force to composite material 206 byfirst number of compliant elongate members 242 and second number ofcompliant elongate members 256 during shaping of composite material 206onto base 216.

Base 216 may take the form of at least one mold. In one illustrativeexample, base 216 is female mold 272. In another illustrative example,base 216 is number of male molds 274. In some illustrative examples,number of male molds 274 is two male molds. When base 216 is number ofmale molds 274, number of male molds 274 may be horizontally movablerelative to each other.

Female mold 272 may be used to form vent stringer 276. Vent stringer 276may be formed by uniformly applying composite material 206 to femalemold 272 using shaping system 232. Number of male molds 274 may be usedto form blade stringer 278. Blade stringer 278 may be formed using twosteps. First, composite material 206 is uniformly applied to number ofmale molds 274 using shaping system 232. Afterwards, a first male moldand a second male mold of number of male molds 274 may be moved towardseach other.

Prior to shaping, composite material 206 may be positioned withincomposite forming tool 202 using carrier 208. Carrier 208 includes frame280 and film 282. Composite material 206 contacts film 282 of carrier208. In other words, film 282 carries composite material 206. Film 282is held taught by frame 280.

Frame 280 may be a rigid structure used for positioning carrier 208relative to composite forming tool 202. Frame 280 includes alignmentfeature 284. Alignment feature 284 is used to align composite material206 relative to shaping system 232 and base 216. In some illustrativeexamples, alignment feature 284 may index frame 280 relative to acenterline of composite forming tool 202. When carrier 208 carriescomposite material 206, centerline presser 238, forming surface 244, andforming surface 260 contact film 282.

In some illustrative examples, composite material 206 may be positionedrelative to shaping system 232 and base 216 without carrier 208. Inthese illustrative examples, centerline presser 238, forming surface244, and forming surface 260 contact composite material 206.

Thus, one or more illustrative examples provide a technical solution tothe technical issues associated with at least one of manual layup ofcomposite parts or currently used composite part layup systems. Thetechnical solution provides a uniform force capable of applying acomposite material ply to a female mold.

Turning now to FIG. 3, an illustration of a physical implementation of amanufacturing environment is depicted in accordance with an illustrativeembodiment. Manufacturing environment 300 may be a physicalimplementation of manufacturing environment 200 of FIG. 2.

Manufacturing environment 300 includes composite forming tool 302 andcomposite material 304. Composite forming tool 302 includes base 306,frame 308, and shaping system 310. As depicted, base 306 is female mold312. Length 314 of female mold 312 extends past the edges of theillustration. Length 316 of shaping system 310 is less than length 314of female mold 312. To apply composite material 304 to length 314 offemale mold 312, frame 308 and associated shaping system 310 aretranslated along longitudinal axis 318 of female mold 312.

Frame 308 translates along longitudinal axis 318 using axial movementsystem 320. In this illustrative example, axial movement system 320takes the form of number of rails 322.

To apply composite material 304 to female mold 312, shaping system 310moves along vertical axis 324. Shaping system 310 may move alongvertical axis 324 towards female mold 312. Shaping system 310 includescenterline presser 326, first force application assembly 328, and secondforce application assembly 330. Centerline presser 326 may be movedalong vertical axis 324 using movement system 332. First forceapplication assembly 328 and second force application assembly 330 maybe moved along vertical axis 324 using number of vertical arms 334.

First number of compliant elongate members 337 of first forceapplication assembly 328 may be moved along horizontal axis 336 usingfirst movement system 338. First number of compliant elongate members337 may be one or more compliant elongate members. In illustrativeexamples in which first number of compliant elongate members 337 is morethan one compliant elongate member, the compliant elongate members areconnected together to form a single forming surface. First movementsystem 338 includes first number of arms 340 and second number of arms342. First number of compliant elongate members 337 moves in at leastone of horizontal axis 336 or vertical axis 324 relative to centerlinepresser 326.

Second number of compliant elongate members 343 of second forceapplication assembly 330 may be moved along horizontal axis 336 usingsecond movement system 344. Second number of compliant elongate members343 may be one or more compliant elongate members. In illustrativeexamples in which second number of compliant elongate members 343 ismore than one compliant elongate member, the compliant elongate membersare connected together to form a single forming surface. Second movementsystem 344 includes third number of arms 346 and fourth number of arms348. Second number of compliant elongate members 343 moves in at leastone of horizontal axis 336 or vertical axis 324 relative to centerlinepresser 326.

First number of arms 340, second number of arms 342, third number ofarms 346, and fourth number of arms 348 extend through plate 350connected to number of vertical arms 334. First number of arms 340extend through second number of compliant elongate members 343. Thirdnumber of arms 346 extend through first number of compliant elongatemembers 337.

Turning now to FIG. 4, an illustration of a cross-sectional isometricview of a composite forming tool is depicted in accordance with anillustrative embodiment. View 400 is a cross-section of compositeforming tool 302 along cross-section 4-4 of FIG. 3.

As depicted, forming surface 402 and forming surface 404 contactcenterline presser 326. First number of arms 340 includes arm 406.Second number of arms 342 includes arm 408. Arm 406 and arm 408 extendthrough plate 350. Arm 406 extends through second number of compliantelongate members 343. Third number of arms 346 includes arm 410. Fourthnumber of arms includes arm 412. Arm 410 and arm 412 extend throughplate 350. Arm 410 extend through first number of compliant elongatemembers 337. As depicted, arm 410 and arm 412 are connected tocenterline presser 326.

Turning now to FIG. 5, an illustration of a cross-sectional front viewof a composite forming tool is depicted in accordance with anillustrative embodiment. View 500 is a view of composite forming tool302 from direction 5-5 of FIG. 4.

As depicted, arm 406 and arm 408 are connected to centerline presser326. Actuator 502 is connected to arm 406 and extends through centerlinepresser 326. Actuator 502 is connected to first number of compliantelongate members 337. Actuator 504 is connected to arm 408 and extendsthrough centerline presser 326. Actuator 504 is connected to firstnumber of compliant elongate members 337. Arm 406, arm 408, actuator502, and actuator 504 control the movement of first number of compliantelongate members 337 along horizontal axis 336.

Arm 410 and arm 412 are connected to centerline presser 326. Actuator506 is connected to arm 410 and extends through centerline presser 326.Actuator 506 is connected to second number of compliant elongate members343. Actuator 508 is connected to arm 412 and extends through centerlinepresser 326. Actuator 508 is connected to second number of compliantelongate members 343. Arm 410, arm 412, actuator 506, and actuator 508control the movement of second number of compliant elongate members 343along horizontal axis 336.

As depicted, first force application assembly 328 and second forceapplication assembly 330 have been lowered. Specifically, centerlinepresser 326, first force application assembly 328, and second forceapplication assembly 330 have been lowered such that centerline presser326 would contact a composite material or carrier positioned withincomposite forming tool 302.

Turning now to FIG. 6, an illustration of a cross-sectional front viewof a composite forming tool is depicted in accordance with anillustrative embodiment. In view 600, first force application assembly328 and second force application assembly 330 have moved from view 500of FIG. 5. Specifically, forming surface 402 and forming surface 404have been moved along surface 602 of female mold 312. Between view 500and view 600, first number of compliant elongate members 337 and secondnumber of compliant elongate members 343 have moved along horizontalaxis 336. During this movement, first number of compliant elongatemembers 337 and second number of compliant elongate members 343 wouldmaintain a uniform amount of force against one of a carrier and acomposite material such that the composite material is uniformly appliedto surface 602 of female mold 312.

Turning now to FIG. 7, an illustration of a cross-sectional front viewof a composite forming tool is depicted in accordance with anillustrative embodiment. In view 700, first force application assembly328 and second force application assembly 330 have moved from view 600of FIG. 6. Specifically, forming surface 402 and forming surface 404have been moved along surface 602 of female mold 312. Between view 600and view 700, first number of compliant elongate members 337 and secondnumber of compliant elongate members 343 have moved along bothhorizontal axis 336 and vertical axis 324. During this movement, firstnumber of compliant elongate members 337 and second number of compliantelongate members 343 would maintain a uniform amount of force againstone of a carrier and a composite material such that the compositematerial is uniformly applied to surface 602 of female mold 312.

Turning now to FIG. 8, an illustration of a cross-sectional front viewof a composite forming tool is depicted in accordance with anillustrative embodiment. In view 800, first force application assembly328 and second force application assembly 330 have moved from view 700of FIG. 7. Specifically, forming surface 402 and forming surface 404have been moved along surface 602 of female mold 312. Between view 700and view 800, first number of compliant elongate members 337 and secondnumber of compliant elongate members 343 have moved along bothhorizontal axis 336 and vertical axis 324. More specifically, betweenview 700 and view 800, first number of compliant elongate members 337and second number of compliant elongate members 343 have moved aroundcorner 802 and corner 804. During this movement, first number ofcompliant elongate members 337 and second number of compliant elongatemembers 343 would maintain a uniform amount of force against one of acarrier and a composite material such that the composite material isuniformly applied to surface 602 of female mold 312.

Turning now to FIG. 9, an illustration of a cross-sectional front viewof a composite forming tool is depicted in accordance with anillustrative embodiment. In view 900, first force application assembly328 and second force application assembly 330 have moved from view 800of FIG. 8. Specifically, forming surface 402 and forming surface 404have been moved along surface 602 of female mold 312. Between view 800and view 900, first number of compliant elongate members 337 and secondnumber of compliant elongate members 343 have moved along horizontalaxis 336. During this movement, first number of compliant elongatemembers 337 and second number of compliant elongate members 343 wouldmaintain a uniform amount of force against one of a carrier and acomposite material such that the composite material is uniformly appliedto surface 602 of female mold 312.

As can be seen from FIGS. 5-9, first number of compliant elongatemembers 337 and second number of compliant elongate members 343 ofshaping system 310 are moved to substantially mirror a number offeatures of the surface of female mold 312. Specifically, formingsurface 402 and forming surface 404 follow the features of surface 602of female mold 312. As used herein, “a number of,” when used withreference to items means one or more items. Further, as can be seen fromFIGS. 5-9, first number of compliant elongate members 337 and secondnumber of compliant elongate members 343 of shaping system 310 are movedsubstantially simultaneously. In this illustrative example, first numberof compliant elongate members 337 and second number of compliantelongate members 343 of shaping system 310 are moved in paths which aresubstantially mirror images of each other.

Turning now to FIG. 10, an illustration of a cross-sectional front viewof a composite forming tool is depicted in accordance with anillustrative embodiment. In view 1000, composite forming tool 1002includes base 1004. Base 1004 takes the form of first male mold 1006 andsecond male mold 1008. First male mold 1006 and second male mold 1008are movable relative to each other.

Composite forming tool 1002 also includes frame 1010 and shaping system1012. Frame 1010 is associated with shaping system 1012. Shaping system1012 is movable relative to frame 1010, base 1004, and a prepregmaterial. To apply a composite material to the length of first male mold1006 and second male mold 1008, frame 1010 and associated shaping system1012 are translated along longitudinal axis 1014 that extends into andout of the page.

Frame 1010 translates along longitudinal axis 1014 using axial movementsystem 1016. In this illustrative example, axial movement system 1016takes the form of number of rails 1018.

To apply a composite material to first male mold 1006 and second malemold 1008, shaping system 1012 moves along vertical axis 1020. Shapingsystem 1012 may move along vertical axis 1020 towards base 1004. Shapingsystem 1012 includes centerline presser 1022, first force applicationassembly 1024, and second force application assembly 1026. Centerlinepresser 1022 may be moved along vertical axis 1020 using movement system1027. First force application assembly 1024 and second force applicationassembly 1026 may be moved along vertical axis 1020 using a number ofvertical arms (not depicted).

First number of compliant elongate members 1028 of first forceapplication assembly 1024 may be moved along horizontal axis 1030 usingfirst movement system 1032. First movement system 1032 includes firstnumber of arms 1034 and second number of arms 1036.

Second number of compliant elongate members 1038 of second forceapplication assembly 1026 may be moved along horizontal axis 1030 usingsecond movement system 1040. Second movement system 1040 includes thirdnumber of arms 1042 and fourth number of arms 1044.

At least one of first number of arms 1034, second number of arms 1036,third number of arms 1042, or fourth number of arms 1044 extend throughportions of composite forming tool 1002. As depicted, first number ofarms 1034 extend through second number of compliant elongate members1038. Third number of arms 1042 extend through first number of compliantelongate members 1028.

First number of arms 1034 includes arm 1046. Second number of arms 1036includes arm 1048. Third number of arms 1042 includes arm 1050. Fourthnumber of arms 1044 includes arm 1052. Arm 1046, arm 1048, arm 1050, andarm 1052 are each connected to centerline presser 1022. Each of arm1046, arm 1048, arm 1050, and arm 1052 are connected to a respectiveactuator that extends through centerline presser 1022. Arm 1046 isconnected to actuator 1054 that extends through centerline presser 1022and is connected to first number of compliant elongate members 1028. Arm1048 is connected to actuator 1056 that extends through centerlinepresser 1022 and is connected to first number of compliant elongatemembers 1028. Arm 1050 is connected to actuator 1058 that extendsthrough centerline presser 1022 and is connected to second number ofcompliant elongate members 1038. Arm 1052 is connected to actuator 1060that extends through centerline presser 1022 and is connected to secondnumber of compliant elongate members 1038.

Turning now to FIG. 11, an illustration of a cross-sectional front viewof a composite forming tool is depicted in accordance with anillustrative embodiment. In view 1100, first force application assembly1024 and second force application assembly 1026 have moved from the viewof FIG. 10. Specifically, forming surface 1102 and forming surface 1104have been moved along surface 1106 of first male mold 1006 and surface1108 of second male mold 1008. Between FIG. 10 and view 1100, firstnumber of compliant elongate members 1028 and second number of compliantelongate members 1038 have moved along both horizontal axis 1030 andvertical axis 1020. During this movement, first number of compliantelongate members 1028 and second number of compliant elongate members1038 would maintain a uniform amount of force against one of a carrierand a composite material such that the composite material is uniformlyapplied to surface 1106 of first male mold 1006 and surface 1108 ofsecond male mold 1008.

Turning now to FIG. 12, an illustration of a cross-sectional front viewof a composite forming tool is depicted in accordance with anillustrative embodiment. In view 1200, first force application assembly1024 and second force application assembly 1026 have moved from view1100 of FIG. 11. Specifically, first force application assembly 1024,second force application assembly 1026, and centerline presser 1022 havebeen retracted. As depicted, forming surface 1102 and forming surface1104 contact centerline presser 1022.

Turning now to FIG. 13, an illustration of a cross-sectional front viewof a composite forming tool is depicted in accordance with anillustrative embodiment. In view 1300, first male mold 1006 and secondmale mold 1008 have moved from view 1200 of FIG. 12. Specifically, firstmale mold 1006 and second male mold 1008 have been moved alonghorizontal axis 1030 towards each other.

In some illustrative examples, a single composite material may be laidup onto first male mold 1006 and second male mold 1008. In theseillustrative examples, moving first male mold 1006 and second male mold1008 along horizontal axis 1030 towards each other may form a bladeshaped stringer by forming a bend in the composite material betweenfirst male mold 1006 and second male mold 1008. In other illustrativeexamples, a first composite material may be laid up onto first male mold1006 and a second composite material may be laid up onto second malemold 1008. Both the first and the second composite material may becarried by a single carrier. In these illustrative examples, movingfirst male mold 1006 and second male mold 1008 along horizontal axis1030 towards each other may form a blade shaped stringer by havingportions of the first composite material contact portions of the secondcomposite material.

In some illustrative examples, after moving first male mold 1006 andsecond male mold 1008 along horizontal axis 1030 towards each other, anadditional composite material may be placed over the composite materialformed into the blade stringer shape. This additional composite materialmay be referred to as a composite charge or a composite base.

Turning now to FIG. 14, an illustration of a carrier and a compositeforming tool in a manufacturing environment is depicted in accordancewith an illustrative embodiment. View 1400 is a view of compositeforming tool 302 and carrier 1402 holding composite material 1404 priorto positioning carrier 1402 within composite forming tool 302.

Turning now to FIG. 15, an illustration of a carrier and a compositeforming tool in a manufacturing environment is depicted in accordancewith an illustrative embodiment. View 1500 is a view of compositeforming tool 302 and carrier 1402 during positioning of carrier 1402. Inview 1500, carrier 1402 holding composite material 1404 has enteredframe 308 of composite forming tool 302.

Turning now to FIG. 16, an illustration of a carrier and a compositeforming tool in a manufacturing environment is depicted in accordancewith an illustrative embodiment. View 1600 is a view of compositeforming tool 302 and carrier 1402 during positioning of carrier 1402. Inview 1600, carrier 1402 is being rotated such that composite material1404 (not shown in this view) will face base 306 of composite formingtool 302.

Turning now to FIG. 17, an illustration of a carrier and a compositeforming tool in a manufacturing environment is depicted in accordancewith an illustrative embodiment. View 1700 is a view of compositeforming tool 302 and carrier 1402 positioned within composite formingtool 302. In view 1700 carrier 1402 has been aligned within compositeforming tool 302 but forming has not begun.

Turning now to FIG. 18, an illustration of a carrier and a compositeforming tool in a manufacturing environment is depicted in accordancewith an illustrative embodiment. View 1800 is a view of compositeforming tool 302 and carrier 1402 positioned within composite formingtool 302. In view 1800, shaping system 310 of composite forming tool 302is being lowered towards carrier 1402 and base 306.

Turning now to FIG. 19, an illustration of a vent stringer formed on acomposite forming tool is depicted in accordance with an illustrativeembodiment. View 1900 of FIG. 19 may be an enlarged view of a stiffenerin stiffeners 120 in section X-X of FIG. 1. As depicted, stiffener 1902is associated with composite skin 122. Stiffener 1902 is a compositepart. Stiffener 1902 as depicted is a vent stringer.

Stiffener 1902 has substantially hat shaped cross-section 1904.Stiffener 1902 is formed of number of plies 1906 which each havesubstantially hat shaped cross-section 1904. Stiffener 1902 may beformed on composite forming tool such as composite forming tool 202 ofFIG. 2 or composite forming tool 302 of FIG. 3. Number of plies 1906 mayeach be successively positioned relative to and shaped by a compositeforming tool. Number of plies 1906 may be shaped one at a time on afemale mold, such as female mold 272 of FIG. 2 or female mold 312 ofFIG. 3.

Turning now to FIG. 20, an illustration of a blade stringer formed on acomposite forming tool is depicted in accordance with an illustrativeembodiment. View 2000 of FIG. 20 may be an enlarged view of a stiffenerin stiffeners 120 in section X-X of FIG. 1. As depicted, stiffener 2002is associated with composite skin 122. Stiffener 2002 is a compositepart. Stiffener 2002 as depicted is a blade stringer.

Stiffener 2002 is formed of a number of plies. Stiffener 2002 may beformed on a composite forming tool, such as composite forming tool 202of FIG. 2 or composite forming tool 302 of FIG. 3. In one illustrativeexample, the number of plies of stiffener 2002 may each be successivelypositioned relative to and shaped by a composite forming tool. Inanother illustrative example, the number of plies of stiffener 2002 maybe simultaneously positioned relative to the composite forming tool andthen shaped simultaneously. Stiffener 2002 may be shaped and formed on anumber of male molds, such as number of male molds 274 of FIG. 2 orfirst male mold 1006 and second male mold 1008 of FIG. 10.

Turning now to FIG. 21, an illustration of a blade stringer formed on acomposite forming tool is depicted in accordance with an illustrativeembodiment. View 2100 of FIG. 21 may be an enlarged view of a stiffenerin stiffeners 120 in section X-X of FIG. 1. As depicted, stiffener 2102is associated with composite skin 122. Stiffener 2102 is a compositepart. Stiffener 2102 as depicted is a blade stringer.

Stiffener 2102 is formed of first composite material 2104, secondcomposite material 2106, and composite base 2108. Each of firstcomposite material 2104, second composite material 2106, and compositebase 2108 is formed of a number of plies. In some illustrative examples,each of first composite material 2104, second composite material 2106,and composite base 2108 are formed of the same number of plies. In otherillustrative examples, at least one of first composite material 2104,second composite material 2106, or composite base 2108 may be formed ofa different number of plies than the others.

Stiffener 2102 may be formed on a composite forming tool, such ascomposite forming tool 202 of FIG. 2 or composite forming tool 302 ofFIG. 3. In one illustrative example, first composite material 2104,second composite material 2106, and composite base 2108 of stiffener2102 may each be successively positioned relative to and shaped by acomposite forming tool. In another illustrative example, first compositematerial 2104 and second composite material 2106 of stiffener 2102 maybe simultaneously positioned relative to the composite forming tool andthen shaped simultaneously. Stiffener 2102 may be shaped and formed on anumber of male molds, such as number of male molds 274 of FIG. 2 orfirst male mold 1006 and second male mold 1008 of FIG. 10.

The illustrations of composite forming tools in FIGS. 3-18 andstiffeners in FIGS. 19 and 20 are not meant to imply physical orarchitectural limitations to the manner in which an illustrativeembodiment may be implemented. Other components in addition to or inplace of the ones illustrated may be used. Some components may beoptional.

The different components shown in FIGS. 1 and 3-20 may be illustrativeexamples of how components shown in block form in FIG. 2 can beimplemented as physical structures. Additionally, some of the componentsin FIGS. 1 and 3-20 may be combined with components in FIG. 2, used withcomponents in FIG. 2, or a combination of the two.

Turning now to FIG. 22, an illustration of a flowchart of a process forforming a composite part is depicted in accordance with an illustrativeembodiment. Process 2200 may be used to form a composite part such ascomposite part 203 of FIG. 2. Process 2200 may be performed on acomposite forming tool such as composite forming tool 202 of FIG. 2 orcomposite forming tool 302 of FIG. 3. The method may begin bypositioning a prepreg material relative to a composite forming tool, thecomposite forming tool comprising a frame associated with a shapingsystem; a base comprising at least one mold; and the shaping systemassociated with the frame and configured to move relative to the frame,the base, and the prepreg material (operation 2202).

The method may then lower the shaping system of the composite formingtool towards the prepreg material (operation 2204). The shaping systemmay be shaping system 232 of FIG. 2. The shaping system may include acenterline presser, a first force application assembly, and a secondforce application assembly. The shaping system of the composite formingtool may be lowered such that the components of the shaping system maybe able to reach the carrier to shape the prepreg material.

The method may then apply pressure to the prepreg material with acenterline presser of the shaping system (operation 2206). In someillustrative examples, by applying pressure to the prepreg material withthe centerline presser, the prepreg material may contact the base. Inthese illustrative examples, the base may take the form of a femalemold. In other illustrative examples, by applying pressure to theprepreg material with the centerline presser, the prepreg material maybe pushed down by the centerline presser without contacting the base. Inthese illustrative examples, the prepreg material may be pulled taut bycontacting the carrier with the centerline presser without the prepregmaterial contacting the base. This illustrative example may be performedwhen the base takes the form of a number of male molds.

The method then applies a force to the prepreg material using a numberof compliant elongate members of the shaping system to uniformly applythe prepreg material to the at least one mold of a base of the compositeforming tool (operation 2208). Afterwards, the process terminates.

To uniformly apply the prepreg material to the base, the force againstthe prepreg material must be substantially uniform as it is applied. Atleast one movement system controls the movement of and force applied bythe number of compliant elongate members. In some illustrative examples,three types of arms may be associated with each compliant elongatemember. For example, a first number of compliant elongate members may bemoved by a combination of a number of vertical arms, a first number ofarms, and a second number of arms.

In some illustrative examples, applying the force to the prepregmaterial using the number of compliant elongate members of the shapingsystem comprises moving the number of compliant elongate members of theshaping system away from the centerline presser along a horizontal axiswhile applying the force. In some illustrative examples, applying theforce to the prepreg material using a number of compliant elongatemembers of the shaping system comprises moving the number of compliantelongate members of the shaping system to substantially mirror a numberof features of a surface of the at least one mold. In some illustrativeexamples, wherein applying the force to the prepreg material using anumber of compliant elongate members of the shaping system comprisesmoving the number of compliant elongate members of the shaping systemalong a vertical axis relative to the centerline presser.

Turning now to FIG. 23, an illustration of a flowchart of a process forforming a composite part is depicted in accordance with an illustrativeembodiment. Process 2300 may be used to form a composite part such ascomposite part 203 of FIG. 2. Process 2300 may be performed on acomposite forming tool such as composite forming tool 202 of FIG. 2 orcomposite forming tool 302 of FIG. 3.

The method may begin by positioning a prepreg material on a carrierrelative to a composite forming tool, the composite forming toolcomprising a frame associated with a shaping system; a base comprisingat least one mold; and the shaping system associated with the frame andconfigured to move relative to the frame, the base, and the carrier(operation 2302). The carrier may be carrier 208 of FIG. 2. In someillustrative embodiments, the carrier comprises a frame and a film. Theprepreg material may be positioned on the film such that the prepregmaterial is facing the at least one mold. The carrier may be centered onthe composite forming tool using an alignment feature of the carrier.The carrier may be aligned relative to a centerline of the compositeforming tool.

The method then lowers the shaping system of the composite forming tooltowards the prepreg material (operation 2304). The shaping system may beshaping system 232 of FIG. 2. The shaping system may include acenterline presser, a first force application assembly, and a secondforce application assembly. The shaping system of the composite formingtool may be lowered such that the components of the shaping system maybe able to reach the carrier to shape the prepreg material.

The method may then contact the carrier with a centerline presser of theshaping system (operation 2306). In some illustrative examples, bycontacting the carrier with the centerline presser, the prepreg materialmay contact the base. In these illustrative examples, the base may takethe form of a female mold. In other illustrative examples, by contactingthe carrier with the centerline presser, the prepreg material may bepushed down by the centerline presser without contacting the base. Inthese illustrative examples, the prepreg material may be pulled taut bycontacting the carrier with the centerline presser without the prepregmaterial contacting the base. This illustrative example may be performedwhen the base takes the form of a number of male molds.

The method then uniformly applies the prepreg material to the at leastone mold of the base of the composite forming tool using a number ofcompliant elongate members of the shaping system. Uniformly applying theprepreg material comprises moving the number of compliant elongatemembers of the shaping system relative to the prepreg material along ahorizontal axis using a number of actuators connected to the centerlinepresser; and applying a force to the prepreg material using the numberof compliant elongate members of the shaping system, wherein the forceis approximately normal to a surface of the at least one mold of thebase (operation 2308). To uniformly apply the prepreg material to thebase, the force against the prepreg material must be substantiallyuniform as it is applied. At least one movement system controls themovement of and force applied by the number of compliant elongatemembers. In some illustrative examples, three types of arms may beassociated with each compliant elongate member. For example, a firstnumber of compliant elongate members may be moved by a combination of anumber of vertical arms, a first number of arms, and a second number ofarms.

The flowcharts and block diagrams in the different depicted embodimentsillustrate the architecture, functionality, and operation of somepossible implementations of apparatuses and methods in an illustrativeembodiment. In this regard, each block in the flowcharts or blockdiagrams may represent at least one of module, a segment, a function, ora portion a combination thereof of an operation or step.

In some alternative implementations of an illustrative embodiment, thefunction or functions noted in the blocks may occur out of the ordernoted in the figures. For example, in some cases, two blocks shown insuccession may be executed substantially concurrently, or the blocks maysometimes be performed in the reverse order, depending upon thefunctionality involved. Also, other blocks may be added in addition tothe illustrated blocks in a flowchart or block diagram.

For example, the method may also retract the number of compliantelongate members and move a first mold of the at least one mold of thebase and a second mold of the at least one mold of the base relative toeach other after retracting the number of compliant elongate members. Insome illustrative examples, moving the first mold of the at least onemold of the base and the second mold of the at least one mold of thebase relative to each other comprises moving the first mold and thesecond mold towards each other.

In some illustrative examples, the method also moves the frame and theshaping system relative to the base following uniformly applying theprepreg material to the at least one mold of the base of the compositeforming tool and positions a second prepreg material relative to thecomposite forming tool after moving the frame and the shaping system. Insome illustrative examples, the method also moves the base relative tothe frame and the shaping system following uniformly applying theprepreg material to the at least one mold of the base of the compositeforming tool and positions a second prepreg material relative to thecomposite forming tool after moving the base.

The illustrative embodiments of the disclosure may be described in thecontext of aircraft manufacturing and service method 2400 as shown inFIG. 24 and aircraft 2500 as shown in FIG. 25. Turning first to FIG. 24,an illustration of a block diagram of an aircraft manufacturing andservice method is depicted in accordance with an illustrativeembodiment. During pre-production, aircraft manufacturing and servicemethod 2400 may include specification and design 2402 of aircraft 2500in FIG. 25 and material procurement 2404.

During production, component and subassembly manufacturing 2406 andsystem integration 2408 of aircraft 2500 in FIG. 25 takes place.Thereafter, aircraft 2500 in FIG. 25 may go through certification anddelivery 2410 in order to be placed in service 2412. While in service2412 by a customer, aircraft 2500 in FIG. 25 is scheduled for routinemaintenance and service 2414, which may include modification,reconfiguration, refurbishment, and other maintenance or service.

Each of the processes of aircraft manufacturing and service method 2400may be performed or carried out by a system integrator, a third party,an operator, or a combination thereof. In these examples, the operatormay be a customer. For the purposes of this description, a systemintegrator may include, without limitation, any number of aircraftmanufacturers and major-system subcontractors; a third party mayinclude, without limitation, any number of vendors, subcontractors, andsuppliers; and an operator may be an airline, a leasing company, amilitary entity, a service organization, and so on.

With reference now to FIG. 25, an illustration of a block diagram of anaircraft is depicted in which an illustrative embodiment may beimplemented. In this example, aircraft 2500 is produced by aircraftmanufacturing and service method 2400 in FIG. 24 and may includeairframe 2502 with plurality of systems 2504 and interior 2506. Examplesof systems 2504 include one or more of propulsion system 2508,electrical system 2510, hydraulic system 2512, and environmental system2514. Any number of other systems may be included. Although an aerospaceexample is shown, different illustrative embodiments may be applied toother industries, such as the automotive industry.

Apparatuses and methods embodied herein may be employed during at leastone of the stages of aircraft manufacturing and service method 2400 inFIG. 24. In particular, composite forming tool 202 and composite part203 from FIG. 2 may be used during any one of the stages of aircraftmanufacturing and service method 2400. For example, without limitation,composite forming tool 202 from FIG. 2 may be used to produce compositepart 203 during at least one of component and subassembly manufacturing2406, system integration 2408, routine maintenance and service 2414, orsome other stage of aircraft manufacturing and service method 2400.

In one illustrative example, components or subassemblies produced incomponent and subassembly manufacturing 2406 in FIG. 24 may befabricated or manufactured in a manner similar to components orsubassemblies produced while aircraft 2500 is in service 2412 in FIG.24. As yet another example, one or more apparatus embodiments, methodembodiments, or a combination thereof may be utilized during productionstages, such as component and subassembly manufacturing 2406 and systemintegration 2408 in FIG. 24. One or more apparatus embodiments, methodembodiments, or a combination thereof may be utilized while aircraft2500 is in service 2412, during maintenance and service 2414 in FIG. 24,or a combination thereof. The use of a number of the differentillustrative embodiments may substantially expedite the assembly, reducethe cost of aircraft 2500, or both.

The illustrative embodiments provide a method and apparatus for atechnical solution to at least one of forming a composite part usingmanual layup of the composite part or using currently availablecomposite part layup systems. The method and apparatus enable automationof a process previously performed by hand. The apparatus enablesautomation by applying substantially uniform force to a prepreg materialas a number of compliant elongate forming members moves across theprepreg material. The number of compliant elongate forming members maysweep outward from a centerline presser to apply the prepreg material.

A number of arms move and provide the force to the number of compliantelongate forming members. Composite forming tool 202 may form compositeparts having a variety of shapes. Further, composite forming tool 202may form female composite parts having desirable quality on femalemolds.

Yet further, composite forming tool 202 has a relatively small footprintin a manufacturing environment. Composite forming tool 202 may reduce atleast one of manufacturing time, manufacturing cost, or inconsistenciesfor forming a composite part such as stringer 204 of FIG. 2.

The method comprises positioning a prepreg material relative to acomposite forming tool. The composite forming tool comprises a frameassociated with a shaping system, a base comprising at least one mold,and the shaping system associated with the frame and configured to moverelative to the frame, the base, and the prepreg material. The methodalso lowers the shaping system of the composite forming tool towards theprepreg material. The method applies pressure to the prepreg materialwith a centerline presser of the shaping system. The method also appliesa force to the prepreg material using a number of compliant elongatemembers of the shaping system to uniformly apply the prepreg material tothe at least one mold of a base of the composite forming tool.

The description of the different illustrative embodiments has beenpresented for purposes of illustration and description, and is notintended to be exhaustive or limited to the embodiments in the formdisclosed. Many modifications and variations will be apparent to thoseof ordinary skill in the art. Further, different illustrativeembodiments may provide different features as compared to otherillustrative embodiments. The embodiment or embodiments selected arechosen and described in order to best explain the principles of theembodiments, the practical application, and to enable others of ordinaryskill in the art to understand the disclosure for various embodimentswith various modifications as are suited to the particular usecontemplated.

What is claimed is:
 1. A method for forming a composite part comprising:positioning a prepreg material relative to a composite forming tool, thecomposite forming tool comprising a frame associated with a shapingsystem; a base comprising at least one mold; and the shaping systemassociated with the frame and configured to move relative to the frame,the base, and the prepreg material; lowering the shaping system of thecomposite forming tool towards the prepreg material; applying pressureto the prepreg material with a centerline presser of the shaping system;and applying a force to the prepreg material using a number of compliantelongate members of the shaping system to uniformly apply the prepregmaterial to the at least one mold of the base of the composite formingtool.
 2. The method of claim 1, wherein applying the force to theprepreg material using the number of compliant elongate members of theshaping system comprises moving the number of compliant elongate membersof the shaping system away from the centerline presser along ahorizontal axis while applying the force.
 3. The method of claim 1,wherein applying the force to the prepreg material using the number ofcompliant elongate members of the shaping system comprises: moving thenumber of compliant elongate members of the shaping system tosubstantially mirror a number of features of a surface of the at leastone mold.
 4. The method of claim 1, wherein applying the force to theprepreg material using the number of compliant elongate members of theshaping system comprises: moving the number of compliant elongatemembers of the shaping system along a vertical axis relative to thecenterline presser.
 5. The method of claim 1 further comprising:retracting the number of compliant elongate members; and moving a firstmold of the at least one mold of the base and a second mold of the atleast one mold of the base relative to each other after retracting thenumber of compliant elongate members.
 6. The method of claim 5, whereinmoving the first mold of the at least one mold of the base and thesecond mold of the at least one mold of the base relative to each othercomprises: moving the first mold and the second mold towards each other.7. The method of claim 1 further comprising: moving the frame and theshaping system relative to the base following uniformly applying theprepreg material to the at least one mold of the base of the compositeforming tool; and positioning a second prepreg material relative to thecomposite forming tool after moving the frame and the shaping system. 8.The method of claim 1 further comprising: moving the base relative tothe frame and the shaping system following uniformly applying theprepreg material to the at least one mold of the base of the compositeforming tool; and positioning a second prepreg material relative to thecomposite forming tool after moving the base.
 9. The method of claim 1,wherein applying the force to the prepreg material using the number ofcompliant elongate members of the shaping system comprises: moving afirst compliant elongate member and a second compliant elongate memberof the number of compliant elongate members in paths which aresubstantially mirror images of each other.
 10. The method of claim 1,wherein applying the force to the prepreg material using the number ofcompliant elongate members of the shaping system comprises: moving thenumber of compliant elongate members substantially simultaneously. 11.The method of claim 1, wherein applying the pressure to the prepregmaterial includes: contacting a carrier holding the prepreg materialwith the centerline presser of the shaping system.
 12. The method ofclaim 1, wherein uniformly applying the prepreg material to the at leastone mold of the base of the composite forming tool comprises:controlling the force applied by of the number of compliant elongatemembers such that the prepreg material is uniformly tacked to the atleast one mold.
 13. The method of claim 1, wherein uniformly applyingthe prepreg material to the at least one mold of the base of thecomposite forming tool comprises: controlling the force applied by afirst compliant elongate member in the number of compliant elongatemembers using a first actuator; and controlling a position and angle ofthe first compliant elongate member in the number of compliant elongatemembers using a number of actuators.
 14. An apparatus comprising: a basecomprising at least one mold; a frame that positions a shaping systemrelative to the base; and the shaping system, wherein the shaping systemis associated with the frame, and wherein the shaping system movesrelative to the frame, the base, and a prepreg material positionedrelative to the base, the shaping system comprising: a centerlinepresser that moves relative to the prepreg material along a verticalaxis to apply pressure to the prepreg material; and a number ofcompliant elongate members that moves relative to the centerline presserand the prepreg material and applies controlled force to the prepregmaterial to uniformly apply the prepreg material to the at least onemold.
 15. The apparatus of claim 14, wherein the number of compliantelongate members moves in at least one of a horizontal axis or thevertical axis relative to the centerline presser, and furthercomprising: a number of actuators which move a first compliant elongatemember of the number of compliant elongate members relative to thecenterline presser.
 16. The apparatus of claim 14 further comprising: anactuator which provides the controlled force for the number of compliantelongate members.
 17. The apparatus of claim 14, wherein the at leastone mold is a female mold.
 18. The apparatus of claim 14, wherein the atleast one mold comprises two male molds that are horizontally moveablerelative to each other.
 19. The apparatus of claim 14, wherein the framemoves relative to the base.
 20. The apparatus of claim 14, wherein thebase moves relative to the frame.
 21. The apparatus of claim 14, whereinthe number of compliant elongate members contact the centerline presserin a resting position.
 22. A method for forming a composite partcomprising: positioning a prepreg material on a carrier relative to acomposite forming tool, the composite forming tool comprising a frameassociated with a shaping system; a base comprising at least one mold;and the shaping system associated with the frame and configured to moverelative to the frame, the base, and the carrier; lowering the shapingsystem of the composite forming tool towards the prepreg material;contacting the carrier with a centerline presser of the shaping system;and uniformly applying the prepreg material to the at least one mold ofthe base of the composite forming tool using a number of compliantelongate members of the shaping system, uniformly applying the prepregmaterial comprising: moving the number of compliant elongate members ofthe shaping system relative to the prepreg material along a horizontalaxis using a number of actuators connected to the centerline presser;and applying a force to the prepreg material using the number ofcompliant elongate members of the shaping system, wherein the force isapproximately normal to a surface of the at least one mold of the base.